Method of making dry batteries



NGV- 27. 1945. A. M, MacFARLAND METHOD 0F MAKING DR-Xv BATTERIES f Filed April so, 1941 A ma A Patented Nov. 27, 1945 UNITED STATES PATENT oFFicE mlll Burgess Battery Company, Chicago, Ill., .a corporation of Delaware Application April 30, 1941, vSerial No. 391,109 8 Claims'.- (Cl. 13S-175) zinc and insulated from the latter, and a suitable electrolyte between the depolarizing mass, which is electrically conductive. and the zinc can. The

' can may be provided with an integral metallic bottom or may be a cylinder open atboth ends such, for example, aslthat described in C. F. Burgess Patent No. 2,231,320. The metal can forms the second electrode. It is ordinarily closed at the bottom and open at the top. After the active mass. including the carbon electrode,

depolarizlng mix, and electrolyte, have been inserted in the can during assembly of the cell, the

o customary -practice is to place a paper washer on the carbon rod to support a seal of wax, pitch,4 or other thermoplastic or fusible sealing material which closes the open end of the can. A space is lett between the depolarizing mass and the washer to provide an expansion chamber into which gases and liquids formed during operation of the cell'may escape. The sealing material is' ordinarily poured in iiuid condition on to the paper washers, each cell being thus individually provided with a seal.

The principal objects of the invention are to simplify the process of manufacturing dry cells and dry batteries and thereby reduc the cost of the nished article, and to avoid the dangers of using paper washer seal supports, as, for example, the short-circuiting'of the cell due-to saturation of the paper by electrolyte. This general objective is achieved by eliminating the paper washer and the steps of applying the washer and pouring the sealing material into the cells, a single, simple sealing operation being substituted as hereinafter more fully described.`

A group of cells may be sealed and joined together into aunitary battery block by means of a single sealing operation. The connecting wires and soldered connections are protected by the same sealing operation.

Further objects of the invention include the provision ot a cell which is completely encased within an inert jacket which prevents escape oi corrosive materials from the interior of the cell; also, the provision oi' a cell having an expansion chamber in either end thereof with provision for side' seams, if any, being sealed so that when the y the relief of pressures which may build up in the expansion chambers.

The many features of advantage in the new method and product disclosed herein will become apparent as the description proceeds.

Fig. 1 is a perspective view.' partly in section, of a dry battery constructed inf accordance with the present invention; l

Fiss. 2, 3 and 4 illustrate, in'transverse section, the battery of Fig. 1,' or parts thereof, in three stages of manufacture, the cells being shown partly in section; and

Fig. 5 illustrates, in perspective, partly in section, a single cell unit embodying the invention.v

The battery of Fig. 1, shown by way of illustration of a particular embodiment of the invention, is formed from a plurality of dry cells l housed within a container formed by trays 2 and I. These trays 'are ordinarily of cardboard impregnated with paramn or other suitable impregnant, this material being customarily used for covering in the battery manufacturing art.

. The cells I are connected in series by means4 of connecting wires 4, lbattery leads 5 and 6 being provided for connection of the external circuit with the end cells of the series. 'I'he invention,

however, is applicable to all batteries, whether K of the A, B, or C type. Thermoplastic or fusible seais l and 'la are used to close the ends of the cells, join them together into a. iirm block. and protect the connecting wires 4 andthe soldered connections of these wires with the carbon electrodes 8 of the cells. I v

Each individual cell l comprises an open-ended metal tube 9, generally zinc containing an active mass, indicated generally by the numeral llt, of well-known composition and including the carvbon electrode, depolarizing mass, and electrolyte paste ina. 'Ihe active masses fill the metal tubes except for small Spaces Il and l2 which are reserved for `gas expansion chambers. The' individual cells are preferably provided with Jackets Vi3 of inert lm material. These Jackets are cylindrical in form, snugly envelop the metal tubes 9, and extend slightly beyond the open ends of the tnb, They are preferably composed of a material which is electrically insulating, some-,- what elastic in the sense that it may be stretched without rupture, and resistant to the corrosive lsalts and solutions contained in the active masses of the Pliofilm," a rubber hydrohalide, rubber, ethyl cellulose, Paralm, and polystyrene are suitable materials. The jackets may be applied to the cellsl in any desired. manner,

and collectively sealed and joined together by" lowering the grouped cells into a shallow body of uid sealing material, permitting the material to harden, then repeating the process to seal the other ends of the cells. This may be done in several different ways all of which involve the essential feature of lowering the inverted cells into the sealing material as contrasted with the present common practiceof pouring the fluid sealing material into the top: of the individual upright cells. The sealing material need not be liquid but should be sunlciently fluid to flow around the cells readily.

In the preferred method, the necessary number of cells are assembled in a suitable form which is adapted to hold them upright and in the form which the battery block will nally assume. Tray 2 may be used for this purpose. The necessary electrical connections are then made between the cells and the battery leads v and 6 are soldered at the proper terminal points. The hattery block is then inverted and lowered (as indicated by the arrow, Fig. 3) into cover tray 3 which contains a shallow body of fluid sealing material 1 as shown in Fig. 2. This operation is illustrated in Fig. 3. Leads 5 and 6 are Drought out as the wired ends of the cells enter tray 3 to be available for connection to the battery terminal posts, not shown. -Any suitable sealing material may be used, although it is preferable, for the reasons hereinafter stated, to use a. substance which will remain somewhat plastic at normal temperatures at which the battery is to be operated. The sealing material 'l is hot and therefore relatively uid when the battery block is lowered into it. As the cells enter the body of sealing material, it is forced up around and between the cells. This results from the displacement of the material by the cells, since the sealing material extends into the interior of the cells only slightly because of the ail: pressure in the spaces at the ends of the cells which are comi pletely closed upon engagement of the ends of the jackets with the sealing. material. In this way, the seal is caused to rise around the cells to a point determined by theoriginal depth of the body of thermoplastic material and the depth of immersion of the cell block into it.

Following this sealing operation, the sealing material is permitted to cool and the partly sealed battery, from which the temporary form 2 has been removed, may be inverted and lowered into tray 2 into which has been poured a quantity of uid sealing material 1a. This step is illus-- trated in Fig. 4. The battery is now completely sealed and covered. When the sealing material has completely cooled, the battery is solid and stiff. There is no opportunity for air pockets or bubbles to form in the sealing material or between it and the cover trays. Outer surfaces are smooth and cemented to the seal. The individual cells are completely closed. 'Leads 5 and 6 may be brought out between the cover lcells maybe assembled in the ilrst instance in a tray which is to form a part of the permanent covering and which contains the sealin'g material. In the latter case, the tray should be kept on a hot surface until all the cells have been placed in the form. The sealing would then be completed after the cells'had been connected together by lowering the top portion into the second cover tray containing fluid sealing material.

As above indicated, the entrapped air at the ends of the cells provide expansion chambers in the nished product. If the cell jackets terminate at the ends of the tubes, or only very slightly beyond, the sealing material will reach at least the ends of the tubes so that the expansion chambers are entirely within the tubes. If, however, the jackets extend a substantial distance beyond the ends of the tubes, say 1/8 to 1% inches, the greater part of the expansion chambers may be within the jacket extension and beyond the ends of the tubes. If a sealing material which remains somewhat plastic at normal temperatures is used and if the jacket material is elas- `tric, a means is provided for the relief of excessive pressures which may occur in the expansion chambers during unusually heavy electrical drain periods. Both the plastic sealing material and the jacket will give, as a result of the force of the'gas pressure, so that the gases may escape between the metal tube and the jacket into spaces between the cells formed by the stretching of the jackets along-the mid-portions of the cells. Considerable volumes of gases may be accommodated in this way without rupturing the protective cell casings.

A single cell embodiment of the invention is illustrated in Fig. 5. This unit may be assembled in a. manner similar to that above described.

'I'he cell comprises a metal tube I4 containing an.

' .preferably of suilicient length to4 cause it to extrays of the battery -where they will be` available for the application of suitable terminal posts or clips. The joint between trays 2 and 3 may be sealed with a suitable gummed tape, if desired. The battery may. of course, be further covered or labeled as desired. Y

In alternative methods for assembling the battend -into the sealing material to thereby strengthen the cell. The unit Is completed by inserting it in inverted position into a cover 23 which also contains a suitable amount of fluid sealing material 24. A second expansion chamber 25 is thus provided and the unit is complete.

Because of the extension'of jacket I6 beyond the lower end of metal tube I4 of the cell, the sealing' material 2| seals the bottom of the cell by closing the open end of the jacket. The seal does not reach the tube. As pointed out above. this arrangement permits gases to escape from expansion chamber I9 between tube I4 and jacket Il into the space between the cell and outer box 20 as the jacket is stretched. f

In addition to the economies in manufacture resulting from the present invention, many other advantages are evident. The carbon electrodes,

sedeva are not disturbed by the sealing operation, whereas the application of a relatively stift paper washer in prio; practices may cause a shifting of the carbon and consequent impairment of electrical contact with the depolarizing material. 'I'he invention is applicable to the sealing of cells having cans with integral metal bottoms although such cells are not illustrated in the drawing. Such cells need not be similarly oriented in the battery block; that is, part of the cells may open at the top oi.' the block while others may be inverted and open downwardly.

I claim:

1. The method of sealing dry cells of the type including a metal tube having at least one end open and concurrently forming an expansion chamber at an open end of the tube, said tube having a jacket of elastic inert illm material around` the tube and extending beyond the open end of said'tube. said method comprising lower.- ing the Jacketed cell with the open end oi' the tube foremost int'o a body of iluid sealing material until the end 'of the jacket is submerged therein. 4

2.. The method of sealing dry cells of the type including a metal tube having at least one end open and concurrently forming an expansion chamber at an open end of the tube, 'said tube having a jacket of elastic inert lm material around the tube and extending beyond the open end of said tube. said method comprising lowering the jacketed cell with the open end o!4 the tube foremost into a body of u'id sealing material until substantially all oi thatv portion of the jacket which extends beyond the end of the tube is submerged therein.

3. The methodof sealing dry cells of the type including a metal tube having at least one end open and concurrently forming an expansion chamber at an open end of the tube, said tube having a jacket of elastic inert iilm material around the tube and extending beyond the open end of said tube, said method comprising lowering the jacketed cell with the open end of the` tube foremost into a body of iiuid sealing material until all of that portion of the jacket which extends beyond the end of the tube and at least a part of that portion of the jacket which is around the tube is submerged in the sealing mas terial,c said sealing material having a normally plastic consistency.

4. The method of making a dry' battery irona plurality of dry cells having at 'least one end thereof unsealed and having jackets which extend beyond the metal tubes of the cells atthe u hlll'dem unsealed ends; said method comprising the steps of assembling the cells into a battery block and thereafter lowering saidblock, unsealed ends of cells foremost. into a shallow body-of iluid sealing material until at least the ends of the projecting jackets are submerged in the material.

5. The method of making a dry battery from a plurality of dry cells having at least one end thereof unsealed and having jackets which extend beyond the metal tube of the cells' at the unsealed end, said method comprising the steps of assembling the cells into a battery block and thereafter lowering said block, unsealed ends of cells foremost, into a shallow body of iluid sealing material confined in a tray until the material is caused to rise around said cells at least to the level of the ends of the tubes of the cells, and thereafter permitting the sealing material to harden to a normal plastic consistency.

6. The method of sealing dry cells of the type including a metal tube and concurrently forming anA expansion chamber at an open end of the tube, said tube having a jacket of elastic inert lm material therearound and extending beyond the open end of said tube, said method comprising lowering thevjacketed cell with the open end of the tube foremost into a body of fluid sealing material to such an extent that the sealing material enters the open end of said jacket but does not reach said tube.

7. 'I'he method of sealing a di-y cell of the type including a cylindrical metaltube having an open end comprising wrapping the cell with an elastic inert illm material to form a cylindrical jacket extending to an open end beyond the open end oi' said tubesealing the walls of said Jacket to render them substantially liquid-tight, sealing the open end oi said jacket by lowering the jacketed cell with the open end o! the Jacket forel most into a body of nuid sealing material until the end oi' the iacketis submerged therein, and

snowing said sealing material to harden.

8. The method of sealing a dry cell oi' the type j including a cylindrical metal tube having an open end comprising wrapping the cell with an elastic inert nlm material to form a cylindrical jacket extending to an open end beyond the open end of said tube, sealing the walls of said jacket to render them substantially liquid-tight. sealing the open end of said jacket by' lowering the iacketed cell with the open end of the jacket v foremost into a body of uid sealing material to such an extent that the sealing material enters the open end'of said jacket but does not.AL reach said tube, and allowing said sealing material to .l ALI-ISDN M. MACFARLAND. 

